Beruflich Dokumente
Kultur Dokumente
Sep - 2014
PIPING INSTRUCTION * SHIPBUILDING
CONTENTS:
1. INTRODUCTION
2. PIPING THEORY and INTRODUCTION TO P&IDs Page
2.1 Piping basic Page 5
2.1.2. Materials
2.1.2. Standards
2.1.4. Pipe system classes by DNV
2.1.3. System Diagrams – P&IDs
2.1.4. Piping drawings
2.1.5. SFI System
2.2. System Diagram Introduction – P&ID Page 8
2.2.1. Going through one typical P&ID
2.2.2. Pipeline components
2.2.3. Introduction to main system diagrams - System by system
2.2.3.1. Cargo systems
2.2.3.2 Machinery Systems & Other Systems
2.2.4. Special equipment and Expressions
2.2.5. Corrosion protection
3. PIPING ON BOARD
3.1. Fabrication of PT-pipes Page 30
3.1.1 Planning
3.1.2. Measuring of the pipes
3.1.3. Make an ISO drawing of your pipe (hand sketch)
3.1.4. Bending with the bending machine
3.1.4.1. Installing of the sealing
3.1.5. Cleaning of the pipe
3.1.6. Installation of supports
3.1.7. Working on board
3.2. Fabrication of Steel pipes Page 39
3.2.1. Planning
3.2.2. Building of ISO pipes
3.2.3. Pipe building on board
3.2.4. Make an ISO drawing of your pipe
3.2.5. Calculation
3.2.6. Building of pipes
3.2.7. Preparing
3.2.8. Start the work
3.2.9. Tag welding of flanges
3.2.10. Working on board
3.2.11. Site run of last spool before equipment
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PIPING INSTRUCTION * SHIPBUILDING
CONTENTS:
3. PIPING ON BOARD
3.1. Fabrication of PT-pipes
3.2. Fabrication of Steel pipes
3.3. Some common routing problems to be aware of (for all pipe fitters)
3.4. Pipe erection by block Page 48
3.4.1. Pre-outfitting
3.4.2. Pipe erection by module
3.4.3. Pipe erection with isometric drawing (ISO) and P&ID drawing
3.4.4. Setting of supports
3.5. Cleaning, testing and coating of piping systems Page 58
3.5.1. Pipe cleaning inside
3.5.2. Pipe coating/preservation
3.5.3. Pressure testing
3.5.4. NDT testing (Non Destructive Testing)
3.5.5. Flow coding
3.6. Yard standard for piping components Page 60
3.6.1. Bulkhead and deck penetration
3.6.2. Overboard pipes
3.6.2.1. Overboard pipes and sleeves
3.6.3. Bended pipes and Elbows
3.6.4. Branch line connection with "saddle" or "T-pipe"
3.6.5. Reducers
3.6.6. Drains
3.6.6.1. External drains
3.6.6.2. Internal drains
3.6.7. Pipe supports / Clamps
3.6.8. Pipe joint methods
3.6.8.1. Pipe to flange with slip-on flange
3.6.8.2. Pipe to flange with welding neck flange
3.6.8.3. Pipe to flange with welding collar in combination with a slip-on flange
3.6.8.4. Pipe to pipe joint with Straub Grip coupling
3.7. Tank accessories Page 68
3.7.1. Tank sounding
3.7.2. Level alarm
3.7.3. Heating coils
3.7.4. Steam injection
3.7.5. Temperature sensor
3.7.6. Sampling point
4. TYPICAL DRAWING SYMBOL Page 74
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PIPING INSTRUCTION * SHIPBUILDING
1. General introduction
- This handbook is developed with the aim to be a support for the worker/pipe fitter, for the
foreman and also for the engineer. The handbook is on the whole fairly elementary, being a
reference guide with methods, solutions, key points and alternatives.
- It is the base handbook for a training program for pipe fitters and alternatively for the
engineers.
- Not many standards, etc. are included in the manual, although there are some in the
appendix. To include all common standards for the pipe fitter the handbook would be quite
comprehensive. Please refer to the catalogue from Brodrene Dahl or other relevant
handbooks
2. containing
PIPING THEORY andstandards etc. TO P&IDs
INTRODUCTION
2.1 Piping basic
2.1.2. Materials
• Piping material to be used is decided in the building specification for the ship.
• Piping material with information about standards and dimensions are given on the
different Pipe system diagrams.
• The common types are as follows:
- Steel, St. 37, Seamless. Galvanized or not galvanized.
+ Main cargo systems
+ Fresh water cooling
+ Bilge system
+ Fire system
+ Drain system
+ And others….
- Stainless steel, type Blucher
+ Sanitary discharge
- Copper Nickel, CuNi10Fe
+ For SW cooling
- Copper, plastic coated
+ Sanitary supply pipes (small dimensions)
- Stainless steel, AISI 316
+ For methanol system
+ For remote sounding inside tanks
+ For hydraulic system wet area SW exposed (=<ND25)
- Precision steel tubes, DIN 2391 (various materials)
+ Hydraulic piping (small diameters)
+ Compressed air (small diameters)
+ FO system (small diameters)
+ LO system (small diameters)
+ and other systems
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• Ejectors
- Same function as a pump
+ Creates a vacuum pressure
+ Cheap and simple construction
+ Powered by waterflow or by airflow.
+ Used for emptying cofferdams for water
+ Used for emptying BHS tanks
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PIPING INSTRUCTION * SHIPBUILDING
• Heat exchanger
- A heat exchanger is transferring heat from one medium to another.
- In principle the same as a cooler.
• Filters
- Threaded or flanged?
+ Basic rule is to use flanged for sizes from ND50 and up
+ Threaded connection for sizes below ND50
+ For fuel oil it is restriction from class to use threaded connection
- Y-filters
+ Used for fluids which requires fine filtering such as FW water, fuel oil,
compressed air and more.
+ Normally to be mounted in horizontal pipeline with filter/bonnet down
+ Important to prepare space below for filter changing and access to the filter.
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PIPING INSTRUCTION * SHIPBUILDING
Mudbox Bilge
Straight type
Mudbox Bilge
Angle type
Mudbox for
Mud, Brine
system
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PIPING INSTRUCTION * SHIPBUILDING
- Ball valve
+ Open/close valve. Simple and practical.
+ Mostly used for dimensions below ND40. Threaded type.
- Butterfly valve
+ Open/close valve.
+ Mostly used for dimensions from
ND40 and up. Flanged type.
+ LUG type. Bolted to flanges on both
sides of the valve.
• Very common valve on cargo
systems
• Can be used as dead-end flange. Butterfly
+ Wafer type. To be mounted between Butterfly valve,
valve, LUG
flanges. Wafer type
type
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• On tanks containing fuel oil, base oil or lub oil and is ventilated directly to
open air, a vent valve with flame screen is required. Flame screen is a
perforated steel plate designed to prevent fire to pass through the
screen.
• On ventilation of mud and brine tanks a special type of vent. valve is
necessary to use. If mud is overflowing in the tank, a normal vent. valve
does not have enough opening for mud to escape and the tank can be
deformed because of high pressure, and eventually start leaking.
• This valve has built in a non-return flap valve, see drawing below.
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PIPING INSTRUCTION * SHIPBUILDING
TA valve,
TACO Setter valve
Incl. Shut-off
function
- Globe valve:
+ Open/close valve but normally used
where there is need for some
regulating of the flow.
+ If fine regulating is necessary, a
conical shape of the "plug" can be
used.
+ Not suitable where full opening is
- Gate valve:
+ Open/close valve that is suitable where full opening is necessary.
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PIPING INSTRUCTION * SHIPBUILDING
- Sounding valve:
+ A type of self closing valve
developed for use on manual
sounding pipes.
+ Normally delivered with a pedal so
that the valve can be opened
with the foot.
+ A counterweight is closing the
valve.
- Solenoid valve:
+ A magnet operated
valve. An electrical
signal is activating
a magnet that is
opening or closing the
solenoid valve.
+ Used f. ex. on all valve
actuators.
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PIPING INSTRUCTION * SHIPBUILDING
• Safety components:
- Pressure alarm and Temperature alarm
+ This is constantly feeling the pressure or temperature in a piping system and
giving an alarm signal when preset limit (high or low) is exceeded. Alarm
signal is normally to ship's alarm and monitoring system
- An overflow pot can be mounted to an overflow system (on FO and LO system).
When one of the tanks connected to this system goes in overflow, fluid will go
through the overflow piping and overflow pot, and create an alarm signal.
- High level alarm is mounted on most of the tanks.
• Components for measuring and controlling:
- Temperature sensors
+ Thermometer
• Thermometer is a device for local indication of the temperature.
• Normally mounted before and after a cooler or heat exchanger.
+ Digital temp. sensor
• Sensor that gives an electric signal when reaching a set limit.
Signal can be used for alarm, for autostart of other
equipment or other.
+ Analog temp. sensor
• Sensor for accurate temp. reading.
Normally 4-20 mA signal for remote reading/controlling.
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PIPING INSTRUCTION * SHIPBUILDING
• Actuator:
- An actuator is mounted on a valve for remote operation of
the valve.
- All actuators are connected to the ships control and
monitoring system so that the operator in Engine Control
Room can see the position of all valves connected to the
system and can open/close them remotely.
- Pneumatic or Electric type
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PIPING INSTRUCTION * SHIPBUILDING
• Couplings:
- Very often a standard type of coupling is described to be mounted on the end of a pipe.
- All cargo systems have specified couplings prepared on pipe ends in cargorail/outside which
will fit directly to the hose coupling standard on platforms/rigs.
- There is a large variety of different couplings.
• Sockets / muffs:
- Equipment mounted to the pipeline such as pressure sensors, temperature
sensors, etc. need a socket/muff (f. ex. ½" with internal threads) on the main
line to be mounted to.
- It is important that the sockets are included in the ISO drawings from the beginning
so that it is ready for the outfitter onboard to mount the sensor. If not it will be
welding on the pipe after mounting onboard. Specially on galvanized pipes this shall
be avoided.
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• Compressed Air System (Starting air and Instrument air): ( SFI: 731 )
- Compressed air system is generating compressed air and distributing air at 30 bar
or less to consumers.
- Main consumers for starting air (30 bar) are starting air for main engines,
typhoons, quick closing valves and purge system for wheelhouse windows
washing system.
- Main consumers for instrument air (7 bar) are instrument air for main engines,
separators for FO/LO/bilge, pneumatic actuators (for valves), expansion tanks
and tank sounding system.
- Instrument air must be dried in air dryers otherwise fine consumers can be
damaged from moisture.
- Main components are starting air compressors, starting air receivers (bottles), air
dryers, instrument air receiver and pressure reduction station.
• Working Air System: ( SFI: 732 )
- Working Air System is generating air and distributing air at 7 bar to consumers.
- Main consumers are many working air outlets, air ejectors for pumps, blowing air
in sea chest, incinerator and possibly others.
- Main components are working air compressor and working air receiver,
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• Purging:
- Purging is an expression used f. ex. for methanol system. Methanol is extremely
fire hazardous. After methanol has been pumped through the pipes it is
necessary to empty the pipes for methanol damp. Then an inert gas is used,
normally nitrogen, to blow the pipes clean. When pipes are filled with nitrogen
gas it is safe.
• E0 list:
- E0 is a DNV class notation meaning unattended machinery space.
- E0 list is a listing of all alarms, surveillances, requirements, etc. necessary to have
to be able to operate the ship with unattended machinery space.
• Torsional vibration calculations:
- When having a classical propulsion arrangement with engine, propeller shaft,
sterntube, propeller and perhaps intermediate shaft and gearbox, a complex
calculation is necessary to hinder that any part in the system is coming
into its own natural frequency vibration. If this is not done it is a high possibility
that a part in the propulsion system will vibrate to a level that is not
acceptable. Vibration, noise, excessive wear and breakdown of parts will
be the result.
- The calculation can be done by engine supplier or supplier of the elastic coupling
(between engine and gearbox).
- The calculation has to be checked and approved by DNV.
• Pressure drop calculations:
- When a liquid is pumped through a pipeline, there is resistance to the flow from
the friction inside the pipe, from each bend and if the liquid is lifted to a
higher elevation. The longer and thinner the pipe is, the more pressure drop.
- A pressure drop calculation is a calculation of how much pressure is lost through
the pipe. From tanktop level up to cargo station on main deck, the pressure
can easily drop 2-3 bar.
• See also DNV Rules, Part. 5, Ch. 3, Sec. 1, B100 for useful definitions.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.1 Planing
• Check the drawings and plan where you want to erect the pipes
• PT pipes do not have ISO drawings, all routing must be planned by yourself
• Planning of routing for many or all systems is recommended
• Check what is recommended for this system (size, material, routing, pressure)
EXAMPLE:
FW cooling System
-all pipes in steel
-pipes to be cleaned by blowing with air
-all valves to have easy access
-de-airing to have a upward gradient to the
expansion tank and no air pocket
-Work pressure = 6bar
-test medium = air or water
• Check also how many pipes you will run in this area and take it into the planning
DO NOT GOOD
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.1 Planing
• Check that you are not blocking main entrance, valve handles or further
DO NOT GOOD
Pipes blocking handle Pipe are routed away from the handle
DO NOT GOOD
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.2 Measuring of the pipes
• Pipes have to be routed straight and close together other pipes
NOT GOOD OK
The pipe left from the pillar is not Here are all pipes in a block
together with the other pipes
• Take a good measuring
• Use a minimum of fittings
• Do not lay coupling side by side
DO NOT GOOD
Coupling are side by side and can not Couplings can be easily reached with
be reached with a key tools
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.2 Measuring of the pipes
• The supports are to be planned in the same time
• It is always easier to bend a pipe instead of building long and difficult supports
3.1.3 Make an ISO drawing of your pipe ( 3.1.4 Bending with the bending
hand sketch ) machine
- make a small iso with a wire
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.4 Bending with the bending machine
• Control the pipe of cuts and dents
• Calculate the length of the pipe
• Change the parts from the machine to the size of your pipe
• Take the pipe inside and measure the first length
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.4 Bending with the bending machine
• Set on the bending radius on the digital pad (90) +the extra radius (2.3) (list from the
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.4 Bending with the bending machine
3.1.4.1 Installing of the sealing
! Before you go to this step, the ends of the pipes must be clean and
• There are two different types of connections at STX Vietnam Offshore:
1. Cutting ring
The ring is pressed on the pipe with big pressure and must be pressed on with the
Bending machine
2. Walform
A machine form a ring on the pipe with very high pressure must be pressed on with
the Walform machine.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.5 Cleaning of the pipe.
• Every pipe must be cleaned by air and oily pipes additional by a sponge (see 000-
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.1 Fabrication of PT-pipes
3.1.6 Installation of supports.
• Support always together if possible
• Small pipes can be supported on big pipes (not reverse)
DO NOT GOOD
Before After
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.1 Planning
• Check the drawings and plan the erecting of the pipes
• Check what is recommended for this system (size, material, routing, pressure)
EXAMPLE:
a) Planning:
- check the drawings and plan the erecting of the pipes
- Check what is recommended for this system (size, material, routing,
pressure)
EXAMPLE:
PIPES SPECIFICATION.
PIPING SYSTEM CLASS: |||
PIPE PRESSURE CLASS: PN16.
DESIGN WORKING PRESSURE: 7 BAR
TEST PRESSURE: 10, 5 BAR.
PIPE TYPE ACC. PIPE DIM.: ND < 40:
DIN 2391 PRECISION STEEL TUBES. St. 37.4 (On weather deck to be of
stainless steel).
ND =<150:`` DIN 2501 SEAMLESS STEEL PIPES St. 37.0/St. 35.8.1 (w/3.1 B.
cert,)
ND =>200: DIN 2501 SEAMLESS STEEL PIPES St. 37.0/St. 35.8.1 (w/3.1 B.
cert,)
DNV product certificate for all overboard valves and valves on collision
bulkhead according to
DNV Pt.4 Ch.6 Sec 2 and Pt.4 Ch.6 Sec. 6 C300.
FLANGES/THREADS SPECIFICATION.
FLANGE CONNECTIONS TO BE USED FOR PIPE DIMENSION DN >= 40 AND
UPWARDS,
FITTINGS WITH THREADS, PRESS OR CUT RING TO BE USED FOR PIPES LESS
THAN ND < 40.
FLANGES FOR PIPE DIM. ND =<150: NS 2527 PRESSURE RATING PN16.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.1 Planning
• Check the drawings and plan the erecting of the pipes
• Check what is recommended for this system (size, material, routing, pressure)
EXAMPLE:
NOTES.
1. RECIRCULATION LINE TO BE POSITIONED AS CLOSE AS POSSIBLE TO THE
TOP OF THE TANK AND TO END AGAINST THE BULKHEAD.
2. FILLING/DISCHARGE STATIONS TO BE EQUIPPED WITH 5" COUPLINGS,
WECO / BEST.
3. HORIZONTAL PUMP SUCTION LINE.
4. THE GALVANIZING OF THE PIPING ARE TO BE EXECUTED AFTER ALL
FABRICATION (WORKING UP
AND WELDING) ARE FINISHED.
5.TANKS ABOVE SHELL TO BE FITTED WITH SUCTION BILGE WELLS (see
"SUCTION IN WELLS" detail). SUCTION PIPE IN SHELL TANKS TO BE ENDED
WITH SUCTION BELLMOUTH.
6. ALL VALVES, COCKS AND CONNECTIONS SHALL BE READILY ACCESSIBLE
FOR MAINTENANCE AND
OPERATION. PIPES RUNS SHALL BE DESIGNED FOR EASY REMOVAL.
7. CARGO PIPELINES ABOVE MAIN DECK TO BE ARRANGED IN A WAY TO
ACHIEVE AS GOOD DRAINAGE
AS PRACTICABLE BACK TO TANK. THE HOSE CONNECTION END SHALL NOT
HAVE ITS FACING
DOWNWARDS.
8. PIPELINES GENERALLY TO HAVE SUFFICIENT DRAIN PLUGS.
9. PUMPS TO HAVE LIQUID FILLED PRESSURE GAUGES ON SUCTION AND
DISCHARGE.
10. THE CARGO SYSTEMS TO BE REMOTE OPERATED AND CONTROLLED
FROM BRIDGE AND CONTROL
ROOM.
In case you have a DN 50 pipe to build:
-pipe is 60.3mm x 4.5mm
-pressure rating is PN 16
-the pipe must be send to galvanizing
-when the pipe have a water trap on weather deck, a drain socket have
to be installed
-all valves should have easy access
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.2 Building of ISO pipes
How to calculate the correct cutting length of pipe from spool length on the ISO
drawing.
• You will find all information in the drawing
Spool No.1
The Spool is 3135mm long from middle of the gasket to middle of the gasket
Spool No. 3
The first length is 400mm from the middle of gasket to middle of elbow
Elbow = 18*
the pipe is 383mm – 1.5mm for the half gasket and 2mm for the welding gap
= 379,5mm
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.3 Pipe biulding on board
Some times you have to reroute pipes because of pipe touching or to erect the
last spool before equipment (pump).
• Measure the pipe on board
• Take a good measuring
• Use a minimum of elbows
• Do not block valve handles
• Be aware for pipe touching
100mm
– 5mm (flange)
– 3mm (gasket)
– 76mm (elbow), Check relevant table to
find the building length of an elbow DN 50
= 76mm
– 2mm (welding)
= 14mm 60.3mm pipe
• The second length is 1000mm from the middle of flange to middle of the elbow
You calculate the elbow radius for a 60mm (see appendix 4.4 "bending pipe chart" )
= 36*
1000mm
-106mm (building length of elbow +36* elbow
-2mm (welding gap)
-2mm (welding gap)
-76mm (elbow) = 814mm
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.5 Calculation
• The third length is 600mm from middle of the bend, to end of the offset
The offset can be calculated (see appendix 4.5 "Bends offset chart" ).
= 48* so you need 2 elbows of 48*
The building length must be measured and is = 113mm
600mm
- 113mm
- 2mm (welding gap)
- 2mm (welding gap)
- 76mm (elbow) = 407mm
500mm
- 2mm(welding gap)
- 5mm(flange)
- 3mm (gasket) =490mm
2 flanges DN 50 PN 16
1 elbow 36*
2 elbow 48*
2 elbow 90*
1 pipe = 14mm 60.3mmx4,5mm
1 pipe =814mm 60.3mmx4,5mm
1 pipe =407mm 60.3mmx4,5mm
1 pipe =490mm 60.3mmx4,5mm
Note:
By building a pipe to connect equipment, the flanges must be point welded on
board.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.6 Building of pipes
• Build all pipes in the workshop
• All hot work should be done in the workshop
• Work clean and safety
All fitting must be cut before you start to built the pipe
3.2.7 Preparing
All parts must be cut exactly Elbows have to be cut with the elbow
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.8 Start the working
Grind the pipe and elbows, also the first
25mm By the side of the welding it must be Start to weld the offset together
oil and rust free
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.8 Start of working
• Be always as precise as you can
Take the pipe in level, then use a Check always all sides with a water
water level to get the flange holes level and flange angle tool.
• After measuring, control and cleaning of the pipe, the pipe can be sent to welding
and galvanizing (painting)
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.2 Fabrication of steel pipes
3.2.10 Working on board
NOTE!! NEVER LEAVE A PIPE OPEN!!!!
• Tightening always every bolt/support immediately after installation
• Mark the tightened bolts with a cross
• Check your work one more time
• Clean always your working place after you are finished and, keep it clean!!
• Take only the material on board which you will install on the same day!
• Take care of other workers
Before After
3.2.11 Site run of last spool before equipment
• The last spool of pipe before equipment shall not be produced according to ISO
drawing in the workshop, but be made on site after that the equipment is mounted.
There are always building tolerances on board the ship and if pipes are prefabricated
according to ISO drawing (with theoretical dimensions) this will not fit precisely to
the flange on the pump etc.
• If pipes are prefabricated and forced in place, high stress will be present in the
system, with high risk for breakage some place and problems with
moun ng/demoun ng.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.3 Some common routing problems to be aware of (for all pipe fitters)
Although the steel pipes are built according to ISO drawings and the routing is by
that decided, the piping erector should always bear in mind some important areas:
• There shall be sufficient space around the pipe:
- Below the pipe there shall perhaps be a drip tray. Is there space for this?
- Remember to keep sufficient distance to points where the pipe shall be clamped.
- Shall the pipe be insulated? This requires extra space around the pipe.
- In general the pipes routed along a bulkhead/deck have flanges and the distance
between the flange and the bulkhead should be 1-2 cm. Enough space so that it is
possible to paint underneath.
• To keep in mind and allow space for operation of valve handles. This is important
for the pipe being built and also for pipes located below or behind. Some types of
valve handles have a movement.
• To keep in mind and allow space for mounting of valve actuators. Be conscious to
find the best rotation position for the valve.
• There shall be adequate access to flanges located behind or below the pipe being
built. It must be possible to connect and disconnect all flanges on board after all the
pipes are built.
• The pipe shall not block the way through manholes, hatches or ladders.
• The pipe shall not block the opening of cabinet doors (electro or other).
• Care should be taken if pipes are routed in service spaces for components. It can
be accepted in some cases provided that essential areas are not blocked.
• If a pipe is obviously routed in passage way or escape way, this should be fixed or
reported to a person in charge.
• Any other point that an experienced pipe fitter can think of will be a problem,
should be taken care of or reported to a person in charge.
• It is always better to rectify such bad piping practices in an early stage than to
build the pipe and wait for that somebody else is taking responsibility.
• The vessels are constructed as blocks/units in Hull Factory. Pre-outfitting for piping
is to install pipes and the system components belonging to the block at the block
fabrication stage.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.1 Pre-outfitting
• 3D zone concept is 3D area on the vessel where all piping of designed systems go
through.
• In order to erect pipes with pre-outfitting, the below steps are being followed to
define which spools are erected on what block:
- Define the limit of the block by Frame to Frame with Block/Unit Arrangement
Drawings.
- Define the block containing which 3D zones with Arrangement Drawings.
- Use Piping arrangement drawings of defined 3D zones to know which pipes located
in that 3D zones.
- Take the Isometric drawings of defined spools for construction.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.1 Pre-outfitting
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.2 Pipe erection by module
• The benefit of piping erection by module is saving many man-hours and lifting
equipment. We also can save time for scaffolding building and manual piping
transportation means as using chain block.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• Before erecting spools, make sure that you follow the below steps:
- Prepare all ISO drawings of the 3D zone or area of the system you are going to
erect.
- Put all those ISOs together, connect them together following drawing, then you
know the complete line you are going to erect.
- Make a list for all components on that line (valves, pressure indicator,
thermometer …) following the ISO drawings.
- Study the P&ID drawing to define where that line is located in P&ID.
- Compare your component list with P&ID to make sure there is not any component
missing in your list. For pressure indicator and thermometer, you don’t need to
install them at the beginning, but the sockets for them have to be on the spools.
- Prepare all spools following these ISOs.
- Prepare all valves and other components (if any) according to the component list.
To remind, all sockets for pressure indicators and thermometer have to be on
spools. If you find any sockets missing, please make it just after mounting the spool
on vessel.
- All the sockets and other open ends always to be blinded during and after being
erected.
• Example of ISO preparation: 2002 – 3524 – 401002 (Base Oil system):
- At the end of the spool in this drawing, you see the connection to ISO 2002 – 3524
– 404002
- Take ISO 2002 – 3524 – 404002 you see the connection back to 2002 – 3524 –
401002 and another connecting point to 2002 – 3524 – 404003
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• Example of ISO preparation: 2002 – 3524 – 401002 (Base Oil system):
- At the other end of ISO
2002 – 3524 – 404002,
we see one socket ½”
and a connecting point to
the components
numbered 351.009.10.
- This socket has to be on
the spool before erecting
and plugged properly. If
not, you make it, either
making a socket or
plugging it.
- By learning P&ID
drawing of Base Oil
system, we will know
that 351.009.10 is the 2002 – 3524 – 404002
Pump. FW ( eld weld)
will be only welded when the spool is properly aligned and connected to the pump.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• During erecting piping spools and components:
- Make sure that you erect the spool exactly with the co-ordinate location and
direction showing on ISO. Ex: Fr45 – 130, CL –> PS 1254, Base + 1880 is the co-
ordinate location on 2002 – 3524 – 404002.
- Make sure that there is not any spools and pipes collision.
• For flange connection, make sure that all gaskets have to be greased to prevent
leaking before tightening flanges together.
- Make sure that all the bolts of each flange connection are fitted sufficiently and
properly tightened before you leave this spool to other ones.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.3 Pipe erection with isometric drawing (ISO) and P&ID drawing
• For valves mounting, the below notes have to be followed:
- Make sure that the valve handles can be operated properly. Any collisions are not
acceptable.
- Make sure that the valve handles are not sticking out to the walkway
- All bolts have to be fitted sufficiently and properly tightened.
- After finish mounting a valve, make sure that you try to open and close that valve
one time. All valves have to be 100% opened/closed before you move to other
locations.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.4 Setting of support
Supports "supporting" the pipes and taking vibration and stress from the pipe.
All support must be welded complete
You can find a list of minimum distances for steeel pipes in the appendix 4.4
Also every bend should have a support.
Be aware to not build support with a
like this the water can flow away
water pot/trap
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.4 Pipe erection by block
3.4.4 Setting of support
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.5 Cleaning, testing and coating of piping systems
3.5.3 Pressure testing
• Class (DNV or other) has requirements for pressure testing of each piping systems.
This is to verify the quality of the materials, welding and work of the shipyard in
order to ensure that there are no leakages in the piping systems.
• Always refer to the System Diagram for the specific system or to the drawing "Pipe
Systems, Test and Inspections". Test levels can differ from the levels given in this
diagram, from project to project.
• See drawing No: xxx - 104 - 001 / "Piping system, test & inspection".
3.5.4 NDT testing (Non Destructive Testing)
• Class (DNV or other) has requirements for NDT / X-ray testing of a group of welds
belonging to pipe classes I and II. This is to verify the quality of the welding work
done by the shipyard in order to hinder leakages or fractures in the welds.
3.5.5 Flow coding
• Colour flow code marking for the cargo pipes and main machinery pipes gives
information about the flow direction and which system it is. This is for all pipes
over DN 40. Makes it much easier for the crew to get the overview and have
control.
• The main rule is a distance of
about 3 meters between the
markings which have to be in the
correct colour.
The pipe must be cleaned before
gluing the name tag to the pipe.
After this the colour flow tape must
be glued on the pipe.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.5 Cleaning, testing and coating of piping systems
3.5.5 Flow coding
Flow code colours (possible with some variations in colours from one ship to the
next, depending on the ship operator):
Steam = silver
Bulk handling = black
Bilge = green
Purge Air = blue
Fresh Water = blue
Sea Water = green
Fire = red
Sanitary discharge = black
Fuel Oil = Brown
Liquid Mud = brown
Ballast drill water = green
Oro = brown
Brine = green
Penetration sleeve
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.1 Bulkhead and deck penetration
• To use a bulkhead flange leaves the pipes demountable, which normally is an
advantage.
• Single bulkhead flange (set-on flange) is used when needed to have flange
connection on one side of bkhd and not on the other side (f. ex. with demountable
pipe connection to a tank)
• Double bulkhead flange is used when needed to have flange connection on both
sides of a bkhd or deck, with demountable pipe connections on both sides.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.1 Bulkhead and deck penetration
• Roxtec sealings are DNV accepted for ues in penetration through the deck and
bulkheads that requires watertight or gastight penetration. Roxtec is also used on
chilled water system for thermal insulation between pipe and bulkhead.
Note: Roxtec parts are
expensive, so avoid
using water - or gastight
penetration throught
the beams/deck which
is not require water or
gastight
3.6.2 Overboard pipes
• Special attention is necessary for overboard pipes. This is the pipe going from the
(DNV) classified overboard valve to overboard.
• It is very serious if this pipe is breaking because then seawater can enter
uncontrolled into the vessel.
• The overboard pipe is continuously exposed to a harsh corrosive environment
because:
- Seawater is a salt and corrosive fluid
- The water in the overboard pipe can remain in the pipe for a long time and not
being refreshed with new water, which makes it more acid and corrosive.
- When sleeves are used it is a risk for that seawater is coming into very small
gaps/spaces between pipe and sleeve and becoming more aggressive regarding
corrosion.
• Overboard pipes to have a thickness of min. 11 mm according to DNV.
• After finished welding the overboard pipes, MPI (magnetic particle inspection)
testing should be applied.
• Overboard pipes to be galvanized unless otherwise is specified.
• Supporting brackets to be used between overboard pipe and hull.
3.6.2.1 Overboard pipes and sleeves
• Only penetration sleeves to be used, no
connecting sleeves. To connect an
overboard pipe inside a sleeve is not
accepted by class.
• Overboard pipe to be built completely,
including sleeve, before sending to
galvanizing.
• Thickness of sleeves to be about 10mm.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.3 Bended pipes and elbows
• Elbow standard (commercial type)
- Standard elbow with bending rad. = 1,5 x dia. is the standard method used for
bending a pipe at STX Vietnam.
- Are delivered in 22,5 / 45 / 90 / 180 degrees and other angles can be made out
from these.
- The diameter
of the branch
line can be
equal to or
smaller than the
main line.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.4 Branch line connection with "saddle" or "T-pipe"
• T-pipe connection
- An alternative method of making a branch line is with a "T-pipe" connection.
- The diameter of the branch line can be equal to or smaller than the main line.
- This connection can be used when necessary for making installation easier, etc.
3.6.5 Reducers
• Reducers are used when making a diameter change on a pipeline. Normally
delivered in to 1, 2 or 3 steps below main diameter.
• The 2 types used are concentric type and eccentric type, where concentric is the
most normal.
3.6.6 Drains
• Drain pipes shall not be
routed horizontally, always
with inclination (min. 2%).
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.6 Drains
3.6.6.1 External drains
• Where possible, external drains from one deck to be routed directly above the
drain down to next level.
• All drain pipes to be hot galvanized
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.7 Pipe supports / Clamps
• There is a lot of vibration on board the ship and pipes need to be supported. If this
job is not done properly it is a high risk of that fractures in the piping system will
occur. Pipes that are vibrating are also creating excessive noise.
• All pipes must be evaluated if they need to be clamped. Thick pipes over a short
distance do not need extra support, but most pipes onboard have to be clamped.
Below are shown the most common types of clamps to be used.
- Flat bar pipe clamps (NS 5553):
- Clamps
with
insulation
(because of
heat or
coldness):
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.7 Pipe supports / Clamps
• The piping designer should always do the routing so that clamping is possible. To
route the pipe in the middle of a room is not good. The pipe fitter will sometimes
have to build extra support for the pipe clamp.
• The pipe should not be routed in close proximity to bulkhead or deck in order to
allow adequate space for the pipe support.
• When pipes are insulated, the pipe support should be in contact only with the
insulation, if possible. Ref. illustration above.
3.6.8 Pipe joint methods
• There are many ways how to joint a pipe to a flange or to another pipe. Some of
the methods used in STX are shown below.
3.6.8.1 Pipe to flange with slip-on flange
• A very common way is to weld a pipe to a slip-on flange. The pipe is welded 2
places to the flange. Distance from pipe end to flange end should be 10 mm as a
standard (the same for all pipe thicknesses. See appendix 4.6 for length adjustments
on cutting length for spool, valid for vessel 03 – 06 on STX Vietnam.
• For PN40 a
variation of this slip-
on flange is used;
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.8 Pipe joint methods
3.6.8.2 Pipe to flange with welding neck flange
• To butt-weld a pipe to a welding neck flange is similar to the connection above but
this flange connection is stronger and more solid. The strength ratio is about 2/3 in
favour of the welding neck flange.
• Also recommended for dimensions less than DN40 instead of slip-on flanges.
3.6.8.3 Pipe to flange with welding collar in combination with a slip-on flange
• On SW cooling system there are CuNi pipes in combination with steel flanges, two
different materials which can not be welded together. The way to solve this is to
weld the CuNi pipe on to a prefabricated welding collar of CuNi. A loose flange of
steel, a "slip-on" flange is combined with the collar. Then the pipe end with flange is
ready to be connected to a pump flange or similar.
Welding collar
Slip-on flange
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.6 Yard standard for piping components
3.6.8 Pipe joint methods
3.6.8.4 Pipe to pipe joint with Straub Grip coupling
• It is a method for quick and easy connection and disconnection.
• Can be used for black steel and galvanized steel without damaging the galvanizing
layer.
• Is normally used on the BHS system. Can also be used on other systems.
• Is allowing for some flexibility in pipe alignment.
- Remote sounding
+ For most of the tanks on board it is required by class to have sounding
sensorsgiving a continuous signal/information to the alarm and monitoring system
for the ship.
+ There are different types of remote sounding of the level in a tank, The main
types used for STX ships are:
3. PIPING ON BOARD
3.7 Tank accessories
3.7.1 Tank sounding
+ There are different types of remote sounding of the level in a tank, The
main types used for STX ships are:
• A pneumatic type with pneumatic signal transmittal is measuring the
gravitational pressure in the bottom of the tank.
• An electric sensor with electric signal transmittal.
o Example below is from a mud tank. 2 sensors are installed at
1000mm distance in between. This type is measuring variations
in density of mud and can because of this give a more correct
level indicating at any time.
- Local sounding:
+ This is based on a local system for
reading of the level in the tank. The
main types are:
• Sight glasses mounted on
outside bulkhead of the tank.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.7 Tank accessories
3.7.1 Tank sounding
- Local sounding
+ This is based on a local system for
reading of the level in the tank. The
main types are:
- Manual sounding
This is based on that a sounding
pipe/dipstick or similar is dipped
manually directly down in the tank and
the reading is done when pulling the
dipstick out. A cap has to be removed
from the tank. The 2 types alternatives
are: • Manual screwed cap.
• Sounding cock/valve with
pedal. This is a type of self
closing valve.
3.7.2 Level alarm
• For many of the tanks on board the ship
it is required to have level alarm. It can be
alarm on high level, on low level or for
both high and low level.
• Type of level alarms are:
- Float switch. A float is giving signal when
liquid level is reaching the float. See
different installation alternatives below.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.7 Tank accessories
3.7.2 Level alarm
• Type of level alarms are:
- Electric sensor that is sensing when
liquid is coming into contact.
Lidec L20D
Typ. mud tanks
Lidec
L20-70 DW
Typ. mud tanks
Encl. by other
tanks
- An alarm signal can be taken from the analog signal from the level indicator. But
in many cases class is requirement an signal from an independent sensor/switch.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.7 Tank accessories
3.7.2 Level alarm
• Below is a list of the normal requirements for level alarms for the most common
tanks. The list below is added only for reference, do always check the system
drawings or IO/E0 list for the specific project.
• For ORO tanks it can be a requirement to have steam injection directly into the
tank for heating the collected oil. This is to keep the oil hot and liquefied so that it
will be possible to pump the oil out from the tanks.
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PIPING INSTRUCTION * SHIPBUILDING
3. PIPING ON BOARD
3.7 Tank accessories
3.7.5 Temperature sensor
• For some tanks a temperature sensor is mounted. This is normally done first
mounting a temp. pocket in the tank. Then the temp. sensor is mounted in this.
Advantage with this solution is that it is possible to change sensor without
emptying the tank.
• For some tanks it shall be prepared a possibility to take a sample of the media
from a position outside of the tank.
• This can be done by mounting a 1" socket in the tank near the bottom and
mounting a ball valve directly to this.
• The bulkhead penetration can for some reason be higher up from tank bottom,
then a small pipe on the inside of the tank (to near the bottom) should be
mounted.
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PIPING INSTRUCTION * SHIPBUILDING
Centrifugal pump Screw pump Gear pump W/EL. Propeller pump Diaphragm pump
W/EL. Pump W/EL. Pump Pump W/EL. Pump air driven
Butterfly valve
Butterfly valve Butterfly valve w/Pneum.
Butterfly valve w/Pneum.
w/EL actuator Actuator&spring
Actuator
Butterfly valve
Globe valve NR check valve NR Globe valve Solenoid valve
w/Hydr. Actuator
Page 74
PIPING INSTRUCTION * SHIPBUILDING
Spectacle blind - Spectacle blind - Blind flange valve Blind flange valve 3-way motor
open (Blind flange) close (Blind flange) NC NO operated valve
Page 75
PIPING INSTRUCTION * SHIPBUILDING
Rubber
Orifice Orifice adjustable Flexible coupling Filter
compensator
Mud box Sight glass Liquid seperator Steam trap Hose coupling
Suction piece
Funnel Reducer Blind cover Agitator
( Bell mounth )
Page 76
PIPING INSTRUCTION * SHIPBUILDING
Flow direction
Corrosion piece Hose Bilge well Scupper
arrow
LAH
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PIPING INSTRUCTION * SHIPBUILDING
Page 78